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Home >> Ford >> 2002 >> Focus ZX3, Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 1520 (Rear Drive Axle/Differential - Ford 10.50-Inch Ring Gear -- F250-F350 Super Duty) >> In-Vehicle Repair >> Differential Case >> Installation

Differential Case: Installation

WARNING: This page is about a different car, the 2006 Ford Pickup and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

    All vehicles 

  1. Press the ring gear and, if removed, a new anti-lock speed sensor on the differential case.
    • Tighten to 150 Nm (110 lb-ft).
      Fig 1: Pressing Ring Gear And Anti-Lock Speed Sensor Ring Onto Differential Case
      G03883502Courtesy of FORD MOTOR CO.
  2. Using special thread sealant, install the ring gear bolts.
    • Tighten to 150 Nm (110 lb-ft).
      Fig 2: Identifying Ring Gear Bolts
      G03883503Courtesy of FORD MOTOR CO.
  3. With the pinion depth set and the pinion installed, place the differential case in the rear axle housing.
    • Install a shim on the left side as shown in the illustration.
      Fig 3: Identifying Differential Bearing Shim On Left Side
      G03878553Courtesy of FORD MOTOR CO.
    4. CAUTION: The bearing caps must be installed in their original locations and positions.
    NOTE: Apply pressure toward the left side to make sure the left bearing is seated.
    Fig 4: Identifying Bearing Cap/Bolts
    G03884380Courtesy of FORD MOTOR CO.
  4. Install the left bearing cap and loosely install the bearing cap bolts.
  5. Install progressively larger shims on the right side until the largest shim selected can be assembled by hand.
    Fig 5: Locating Progressively Larger Shims
    G04643880Courtesy of FORD MOTOR CO.
  6. Install the right side bearing cap and tighten the bolts.
    • Tighten to 119 Nm (88 lb-ft).
      Fig 6: Locating Right Side Bearing Cap And Bolts
      G04643881Courtesy of FORD MOTOR CO.
  7. Rotate the differential case to make sure it rotates freely.
    Fig 7: Rotating Differential Case
    G03904430Courtesy of FORD MOTOR CO.

    8. Measuring backlash 

  8. Using the special tool, measure ring gear backlash.
    • If the backlash is within specification, go to  14. The specification shown is the full allowable range. For the preferred range, refer to SPECIFICATIONS .
    • If a zero backlash condition occurs, go to next step.
    • If the backlash is not within specification, go to  10.
      Fig 8: Measuring Ring Gear Backlash Using Special Tool
      G04643883Courtesy of FORD MOTOR CO.

    9. Zero backlash 

  9. If a zero backlash condition occurs, add a 0.50 mm (0.020 inch) shim to the RH side and subtract 0.50 mm (0.020 inch) from the LH side to allow backlash indication. Check backlash. Repeat Step  8.
    THICKNESS REFERENCE

    Backlash Change Required Thickness Change Required
    mm Inch mm Inch
    0.025 0.001 0.050 0.002
    0.050 0.002 0.050 0.002
    0.076 0.003 0.101 0.004
    0.101 0.004 0.152 0.006
    0.127 0.005 0.152 0.006
    0.152 0.006 0.203 0.008
    0.177 0.007 0.254 0.010
    0.203 0.008 0.254 0.010
    0.228 0.009 0.304 0.012
    0.254 0.010 0.355 0.014
    0.279 0.011 0.355 0.014
    0.304 0.012 0.406 0.016
    0.330 0.013 0.457 0.018
    0.335 0.014 0.457 0.018
    0.381 0.015 0.508 0.020

    10. Backlash not within specification 

  10. To increase or decrease backlash, remove the bearing caps and install a thicker shim and a thinner shim as shown.
    • If backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount.
      Fig 9: Locating Differential Bearing Shim
      G04643884Courtesy of FORD MOTOR CO.
  11. Install the bearing caps and bearing cap bolts.
    • Tighten to 119 Nm (88 lb-ft).
      Fig 10: Locating Bearing Caps And Bearing Cap Bolts
      G04643885Courtesy of FORD MOTOR CO.
  12. Rotate the differential several times to make sure the differential bearings are correctly seated.
    Fig 11: Rotating Differential Case
    G03904430Courtesy of FORD MOTOR CO.
  13. Using the special tool, recheck the backlash.
    • If backlash is within specification, go to next step. If not, repeat Step  8.
    • The specification shown is the full allowable range. For the preferred range, refer to SPECIFICATIONS .
      Fig 12: Measuring Ring Gear Backlash Using Special Tools
      G03884451Courtesy of FORD MOTOR CO.

    14. Backlash within specification 

  14. Remove the bearing caps and bolts.
    • To establish differential bearing preload, increase both left and right shim sizes by the specification shown in the illustration.
    • Using the special tool, make sure the differential bearing shims are fully seated and the assembly turns freely.
      Fig 13: Installing Differential Bearing Shim Using Special Tool
      G03904436Courtesy of FORD MOTOR CO.
  15. Install the bearing caps and bearing cap bolts.
    • Tighten to 119 Nm (88 lb-ft).
      Fig 14: Identifying Differential Bearing Cap And Differential Bearing Cap Bolts
      G03878679Courtesy of FORD MOTOR CO.
  16. Using the special tool, verify the backlash.
    Fig 15: Measuring Ring Gear Backlash Using Special Tools
    G03884451Courtesy of FORD MOTOR CO.
  17. Install the axle shafts. For additional information, refer to AXLE SHAFT .
    18. CAUTION: Make sure the machined surfaces on both the rear axle housing and the differential housing are clean and free of oil before applying the new silicone sealant. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination.
  18. Clean the gasket mating surface of the rear axle and the differential housing cover.
  19. Apply a new, continuous bead of silicone sealant to the differential housing cover.
    Fig 16: Proper Application Of Sealant To Differential Housing Cover
    G03878622Courtesy of FORD MOTOR CO.
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